type 8685 / 8686

Operating Instructions

Type 8685/8686

Feedback Head / Control Head Robolux

We reserve the right to make technical changes without notice.Technische Änderungen vorbehalten.Sous réserve de modifications techniques.

© Bürkert Werke GmbH & Co. KG, 2011 - 2018

Operating Instructions 1810/04_EU-EN_00809600 / Original DE

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Tableofcontents

1 OPERATINGINSTRUCTIONS................................................................51.1 Symbols ....................................................................................... 51.2 Definition of term ...................................................................... 5

2 AUTHORIZEDUSE......................................................................................62.1 Restrictions ................................................................................. 6

3 BASICSAFETYINSTRUCTIONS..........................................................6

4 GENERALINFORMATION........................................................................84.1 Contact address ........................................................................ 84.2 Warranty ...................................................................................... 84.3 Information on the Internet ...................................................... 8

5 SYSTEMDESCRIPTION............................................................................85.1 Intended application area ........................................................ 85.2 General description .................................................................. 85.3 Structure of feedback head Type 8685 ............................... 95.4 Structure of control head Type 8686 ................................... 95.5 Structure of adapter set for actuator Type 2036 .............10

6 TECHNICALDATA.....................................................................................106.1 Conformity .................................................................................106.2 Standards ..................................................................................106.3 Operating conditions ..............................................................106.4 Mechanical data.......................................................................116.5 Type label .................................................................................116.6 Pneumatic data ........................................................................116.7 Electrical data for feedback head Type 8685 ...................126.8 Electrical data control head Type 8686 .............................13

7 ASSEMBLY....................................................................................................147.1 Safety instructions ...................................................................147.2 Assembly of Type 8685 and Type 8686 on the actuator Type 2036.................................................................14

8 PNEUMATICINSTALLATION...............................................................198.1 Safety instructions .................................................................... 198.2 Pneumatic installation of feedback head Type 8685 ......208.3 Pneumatic installation of control head Type 8686 ..........20

9 ELECTRICALINSTALLATION...............................................................219.1 Safety instructions ...................................................................219.2 Device version 24 V DC ........................................................219.3 Device version AS-Interface .................................................27

10 CONTROLANDDISPLAY......................................................................3110.1 Control and display elements for feedback head Type 8685 .................................................................................3110.2 Control and display elements for control head Type 8686 ......................................................................................... 3310.3 Control .......................................................................................34

11 SAFETYPOSITIONS................................................................................39

12 MAINTENANCE...........................................................................................3912.1 Safety instructions ...................................................................3912.2 Service at the air intake filter.................................................40

13 MALFUNCTIONS........................................................................................41

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14 SHUTDOWN.................................................................................................4214.1 Safety instructions ...................................................................4214.2 Disassembly..............................................................................42

15 ACCESSORIES...........................................................................................44

16 TRANSPORT,STORAGE,PACKAGING..........................................44

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Operatinginstructions

1 OPERATINGINSTRUCTIONSThe operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is easily accessible to every user and make these instructions available to every new owner of the device.

Theoperatinginstructionscontainimportantsafetyinformation.

Failure to observe these instructions may result in hazardous situations.

▶ The operating instructions must be read and understood.

1.1 Symbols

DANGER!

Warnsofanimmediatedanger. ▶ Failure to observe the warning will result in a fatal or serious injury.

WARNING!

Warnsofapotentiallydangeroussituation. ▶ Failure to observe the warning may result in serious injuries or death.

CAUTION!

Warnsofapossibledanger. ▶ Failure to observe this warning may result in a moderate or minor injury.

NOTE!

Warnsofdamagetoproperty. ▶ Failure to observe the warning may result in damage to the device or the equipment.

Indicates important additional information, tips and recommendations.

Refers to information in these operating instructions or in other documentation.

▶ Indicates an instruction to prevent risks.

→ Designates a procedure which you must carry out.

1.2 Definitionofterm

The term “device” used in these instructions always stands for the feedback head Type 8685 and control head Type 8686.

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Authorizeduse

2 AUTHORIZEDUSE

Non-intendeduseofthefeedbackheadType8685andthecontrolheadType8686maybeahazardtopeople,nearbyequipmentandtheenvironment.

The device is designed to be mounted on pneumatic actuators of process valves for the control of media.

▶ Do not expose the device to direct sunlight. ▶ Use according to the authorized data, service and operating conditions specified in the contract documents and operating instructions. These are described in the chapter on “6 Technical data”.

▶ The device may be used only in conjunction with third-party devices and components recommended and authorized by Bürkert.

▶ In view of the large number of options for use, it is essential prior to installation to study and, if necessary, to test whether the feedback head or control head is suitable for the specific application case.

▶ Correct transportation, storage, and installation, as well as care-ful use and maintenance are essential for reliable and faultless operation.

▶ Use the device only as intended.

2.1 Restrictions

If exporting the system/device, observe any existing restrictions.

3 BASICSAFETYINSTRUCTIONSThese safety instructions do not make allowance for any

• contingencies and events which may arise during the assembly, operation and maintenance of the devices.

• local safety regulations – the operator is responsible for observing these regulations, also with reference to the installation personnel.

Riskofinjuryfromhighpressureintheequipment/device. ▶ Before working on equipment or device, switch off the pressure and deaerate/drain lines.

Riskofelectricshock. ▶ Before working on equipment or device, switch off the power supply and secure to prevent reactivation.

▶ Observe applicable accident prevention and safety regulations for electrical equipment.

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Basicsafetyinstructions

Generalhazardoussituations

To prevent injuries: ▶ The feedback head Type 8685 and control head Type 8686 must not be used in areas where there is a risk of explosion.

▶ Ensure that the system cannot be activated unintentionally. ▶ Installation and maintenance work may be carried out only by authorized technicians with the appropriate tools.

▶ After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a defined or controlled manner.

▶ The device may be operated only when in perfect condition and in consideration of the operating instructions.

▶ The general rules of technology must be observed for applica-tion planning and operation of the device.

To prevent damage to property of the device, ensure: ▶ Do not feed any aggressive or flammable media into the pilot air port for Type 8686

▶ Do not feed any liquids into the pilot air port for Type 8686. ▶ Do not physically stress the body (e.g. by placing objects on it or standing on it).

▶ Do not make any external modifications to the device bodies.

NOTE!

Electrostaticsensitivecomponents/modules.

The device contains electronic components, which react sensitively to electrostatic discharge (ESD). Contact with electrostatically charged persons or objects is hazardous to these components. In the worst case scenario, they will be destroyed immediately or will fail after start-up.

▶ Observe the requirements in accordance with EN 61340-5-1 to minimize/avoid the possibility of damage caused by a sudden electrostatic discharge.

▶ Also, ensure that you do not touch electronic components when the power supply voltage is present.

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Generalinformation

4 GENERALINFORMATION

4.1 Contactaddress

Germany

Bürkert Fluid Control Systems Sales Center Christian-Bürkert-Str. 13-17 D-74653 Ingelfingen Tel. + 49 (0) 7940 - 10 91 111 Fax + 49 (0) 7940 - 10 91 448 E-mail: [email protected]

International

Contact addresses can be found on the final pages of the printed operating instructions.

And also on the Internet at: www.burkert.com

4.2 Warranty

The warranty is only valid if the feedback head and control head are used as intended in accordance with the specified application conditions.

4.3 InformationontheInternet

The operating instructions and data sheets for Type 8685 and Type 8686 can be found on the Internet at:

www.burkert.com

5 SYSTEMDESCRIPTION

5.1 Intendedapplicationarea

The feedback head Type 8685 and the control head Type 8686 are designed to be mounted on pneumatic actuators of valves Type 2036 for the control of media.

5.2 Generaldescription

The feedback head Type 8685 and the control head Type 8686 are designed exclusively for integrated mounting on an actuator of the diaphragm valve Type 2036 in sizes RV50, RV70, RV110.

The actuator size is adjusted with DIP switches.

The valve position is recorded by a permanent magnet on the spindle extension. When a stroke movement occurs, the spindle extension is guided along a reed sensor (lower/upper end position).

In addition to the electrical position feedback, the device status on the feedback head and control head are represented visually by colored LEDs. The status of the integrated pilot valve is also indi-cated by LEDs for the control head.

In the variant with AS-Interface communication, bus status LEDs are also active.

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http://www.burkert.com

http://www.burkert.com

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Systemdescription

5.3 StructureoffeedbackheadType8685

Electrical connection Cable gland M12 x 1.5 or circular plug-in connector M12 x 1

Pressure limiting valve (for protection against too high internal pressure in case of error)

AS interface status LEDs

Drive status OPEN/CLOSED LEDs (end position)

DIP switches Select RV50/70/110

Slide switch Color selection of end position

View without transparent cap:

Fig. 1: Structure of feedback head Type 8685

5.4 StructureofcontrolheadType8686

Dummy plug M16 x 1.5

Electrical connection Cable gland M12 x 1.5 or circular plug-in connector M12 x 1

Pressure limiting valve (for protection against too high internal pressure in case of error)

Exhaust air port (label: 3)

Pilot air port (label: 1)

AS-Interface status LEDs

Actuator status OPEN/CLOSED LEDs (end position)

DIP switches Select RV50/70/110

Slide switch Color selection of end positionSlide switch Pilot valve (Service switch)

Control valve status LEDView without transparent cap and body casing:

Fig. 2: Structure of control head Type 8686

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Technicaldata

5.5 StructureofadaptersetforactuatorType2036

2

5

4

1

7

6

3

9

8

Fig. 3: Adapter set for Type 2036

Item Quantity Designation

1 1 Robolux adaptation body2 6 2 units each Switch spindle RV50, RV70, RV110 cpl. 3 1 O-ring 52 x 3 EPDM 75 4 1 Form seal5 2 Cylinder head screw M6 x 12 A2 DIN 9126 2 Cylinder head screw M4 with shaft7 2 O-ring 3.5 x 1.5 EPDM 708 2 Hose 280 mm9 4 Angular connection G1/8 SL6 Legris

Tab. 1: Parts list for adapter set

6 TECHNICALDATA

6.1 Conformity

The feedback head Type 8685 and the control head Type 8686 comply with EU directives in accordance with the EU Declaration of Conformity.

6.2 Standards

The applied standards, which verify conformity with the EU Direc-tives, can be found on the EU Type Examination Certificate and / or the EU Declaration of Conformity.

6.3 Operatingconditions

WARNING!

Solarradiationandtemperaturefluctuationsmaycausemal-functionsorleaks.

▶ If the device is used outdoors, do not expose it unprotected to the weather conditions.

▶ Ensure that the permitted ambient temperature does not exceed the maximum value or drop below the minimum value.

Ambient temperature 0 – +55 °C

Degree of protection IP65 / IP67 according to EN 60529 (only if cables, plugs and sockets have been connected correctly and in compliance with the exhaust air concept in chapter “8.3 Pneu-matic installation of control head Type 8686”.

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Technicaldata

6.4 Mechanicaldata

Dimensions See data sheet

Body material PPS, PC, VA

Sealing material outside EPDM inside NBR

Stroke range of valve spindle RV50 actuator size 6 mm RV70 actuator size 9.5 mm RV110 actuator size 13.5 mm

6.5 Typelabel

Example:

8686 AS-i S-7.A.E 2x single pilot 3.0 Pmax 7bar Tamb 0 ... +55°C Ser. No. 001000 00XXXXXXD

-746

53 In

gelfi

ngen

W14UN

Identification number

Supply voltage, control or AS-Interface profile

Max operating pressure

TypeControl function, pilot valve

Barcode

Serial number, CE marking

Ambient temperature

Fig. 4: Example of type label

6.6 Pneumaticdata

Control medium neutral gases, air Quality classes in accordance with

ISO 8573-1

Dust content Class 7 Max. particle size 40 µm, max. particle density 10 mg/m³

Water content of Class 3 max. pressure dew point - 20 °C or min. 10 °C below the lowest operating temperature

Oil content Class X max. 25 mg/m³

Temperature range Control medium -10 – + 50 °C

Pressure range Control medium 6 – 7 bar

(for further details see operating instructions Type 2036 and chapter “8.3 Pneumatic installation of control head Type 8686”)

Air output of pilot valve 250 lN / min (for aeration and deaeration) (QNn value according to definition for pressure drop from 7 to 6 bar absolute)

Connections Plug-in hose connector Ø 6 mm / 1/4" Socket connection G1/8

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Technicaldata

6.7 ElectricaldataforfeedbackheadType8685

6.7.1 Electricaldatawithoutbuscontrol24VDC

Connections Cable gland M12 x 1.5, wrench size 15 (clamping area 3 – 6.5 mm) with screw terminals (nominal cross section 1.0 mm², min. cable cross-section 0.25 mm²)

Supply voltage 24 V DC ± 10%, max. residual ripple 10%

Output max. 100 mA per output / short circuit-proof

Display max. 20 mA (2 end positions = 2 LEDs)

6.7.2 ElectricaldatawithAS-Interfacebuscontrol

Connections Remote 975 mm AS-Interface cable with circular plug-in connector (M12 x 1, 4-pole)

Supply voltage 29.5 V – 31.6 V DC (according to specification)

Max. power consumption 35 mA

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Technicaldata

6.8 ElectricaldatacontrolheadType8686

6.8.1 Electricaldatawithoutbuscontrol24VDC

Connections Cable gland M12 x 1.5, wrench size 15 (clamping area 3 – 6.5 mm) with screw terminals (nominal cross section 1.0 mm², min. cable cross-section 0.25 mm²) Circular plug-in connector (M12 x 1, 8-pole)

Pilot valve Supply voltage 24 V DC ± 10% ,

max. residual ripple 10%

Power input 2 x 0.8 W

Output max. 100 mA per output / short circuit-proof

Display max. 20 mA (2 end positions = 2 LEDs)

Service:

Power consumption 90 mA (2 end positions + 2 valves / service switch on)

6.8.2 ElectricaldatawithAS-Interfacebuscontrol

Connections Remote 975 mm AS-Interface cable with circular plug-in connector (M12 x 1, 4-pole)

Supply voltage 29.5 V – 31.6 V DC (according to specification)

Outputs Max. switching capacity: 2 x 0.8 W via AS-Interface

Watchdog function integrated

Max. power consumption 120 mA (2 valves when activated + 2 end positions)

Service:

Power consumption 105 mA (2 end positions + 2 valves / service switch on)

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Assembly

7 ASSEMBLY

7.1 Safetyinstructions

DANGER!




WARNING!

Riskofinjuryfromimproperassembly. ▶ Installation may only be carried out by authorized technicians with the appropriate tools.

Riskofinjuryfromunintentionalactivationofthesystemanduncontrolledrestart.

▶ Secure system from unintentional activation. ▶ Following assembly, ensure a controlled restart.

7.2 AssemblyofType8685andType8686ontheactuatorType2036

An adapter set is required for assembly on the actuator Type 2036.

The adapter set (see “Fig. 3”, page 10) includes an adaptation body, a form seal, three O-rings, four cylinder screws and three switch spindle pairs. There are different adapter sets for feedback head and control head. Because of the different working height for actuator sizes RV50, RV70 and RV110, an adapter set contains different spindle lengths.

Switch spindle Type 8685 Switch spindle Type 8686

RV110 RV70 RV50 RV110 RV70 RV50

Actuator size identification

Cap

Fig. 5: Switch spindle identification

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Assembly

Designation Orderno.

Adapter set for Type 8685 684267

Adapter set for Type 8686 684268

Tab. 2: Adapter sets

Procedure:

Step1:Assemblyofadaptationbodyontheactuator

→ Unscrew the transparent cap from the actuator.

→ Remove cover foil, if present. This makes the coding holes and M6 threads accessible.

→ Place the 52 x 3 O-ring in the profile on the bottom of the adap-tation body.

→ Place the adaptation body on the actuator, paying close attention to the coding pin.

→ Screw the adaptation body tightly onto the actuator with two cylinder screws M6 x 12.

O-ring 52 x 3

Adaptation body

Coding pin

Cylinder screws M6 x 12

Actuator

Fig. 6: Assembly of adaptation body

NOTE!

Usingaswitchspindlethatdoesnotfitwillresultinirrepa-rabledestructionofthefeedbackheadand/orcontrolheadandtheactuator.

▶ Use only switch spindles that match the actuator size. The cor-responding actuator size identification (RV50, RV70, RV110) for switch spindles are embossed on the front of the PVC cap (see “Fig. 5”).

→ Select the switch spindle that matches the actuator size (see “Fig. 5: Switch spindle identification”).

→ Wet the thread of two switch spindles that match the actuator size with Loctite screw locking M290.

NOTE!

Usingthewrongspindlelead-throughwillresultinmalfunction.

▶ Use only the spindle lead-through that matches the actuator size (see “Fig. 7”).

Spindle lead-through for actuator size RV50

Spindle lead-through for actuator sizes RV70 and RV110

Fig. 7: Spindle lead-through

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Assembly

NOTE!

Nodetectionorfaultydetectionofendpositions. ▶ Do not change the position of the cap on the switch spindle. ▶ Use the hole ∅ 2.3 for fastening the switch spindle.

→ Push the switch spindles through the matching spindle lead-throughs. The outside lead-throughs are designed for actuator size RV70/110, while the inside lead-throughs for actuator size RV50 (see “Fig. 7”).

→ Attention: Do not bring the screw locking into contact with the spindle seal.

Hole ∅ 2.3 for screwing in the switch spindle

Form seal

Cap

Fig. 8: Assembly of switch spindles and form seal

→ Using a suitable tool, screw the two switch spindles onto the actuator spindles. There is a hole ∅ 2.3 on the spindle side for this purpose (torque 1.0 Nm ± 0.1 Nm).

→ Place the form seal on the adaptation body (smaller diameter points upwards).

Step2:Assemblyofthefeedbackhead/controlheadontheadaptationbody

If the electrical connection is made with a cable gland, we recommend connecting the wires at this point, since otherwise the feedback head / control head will have to be removed again for the electrical connection.

For electrical installation see: “9.2 Device version 24 V DC” “Device connection for cable gland Type 8685” “Device connection for cable gland Type 8686”

NOTE!

Faultydetectionofendpositions. ▶ For actuators with control function B (CFB, NO), the lower end position must be approached before the feedback head / control head is placed on the adaptation body. To do this, pressurize the appropriate pilot air port of the actuator (“Fig. 9”).

▶ Make certain the feedback head / control head is correctly posi-tioned relative to the actuator: The dummy plug or pressure-relief valve must be located on the side of the pneumatic connections of the actuator (see “Fig. 9”).

→ Place the feedback head / control head on the actuator. As you do, note: - The dummy plug or pressure-relief valve must be located on the

side of the pneumatic connections of the actuator.- The caps must be in the starting position. If not, move the caps

to the starting position (see “Fig. 5”)- The switch spindles must lodge inside the recesses on the bottom

of the feedback head / control head. Do not move the caps onto the switch spindles.

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Assembly

Form seal

Dummy plug

Pressure-relief valve

Connection CFB

Connection CFA

Type 2036

Type 8686 Type 8685

Pne

umat

ic a

ctua

tor

conn

ectio

ns

Switch spindle

Recess

Fig. 9: Assembly of feedback head / control head

→ Push the feedback head / control head onto the adaptation body until no gap is visible on the form seal. Now align the mounting hole of the feedback head / control head on each side with the square nut of the adaptation body.

Fastening screw M4

Mounting hole of the feedback head / control

head concentric with square nut of the adap-

tation body

O-ring 3.5 x 1.5

Fig. 10: Fastening of feedback head / control head

NOTE!

IfthetorqueistoohighwhenscrewinginthefasteningscreworiftheO-ringismissing,degreeofprotectionIP65/IP67isnotensured.

▶ The fastening screw may only be tightened to a maximum torque of 0.5 Nm ± 0.1 Nm.

▶ Check the position of the O-ring.

→ Use the two fastening screws M4 and matching O-rings to fasten the feedback head / control head onto the adaptation body (torque: 0.5 Nm ± 0.1 Nm).

The mechanical connection is already completed for the feedback head after these two assembly steps. “Step 3: Assembly of pneu-matic connection - install the actuator” must still be performed for the control head.

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Assembly

Control head Type 8686 only:

Step3:Assemblyofpneumaticconnection-installtheactuator

→ Screw the plug-in hose connectors onto the control head and the actuator.

→ Cut the enclosed hoses (2 x 280 mm) to length as appropriate for the device layout.

→ Using the hoses supplied in the accessory kit, make the pneumatic connection between the control head and actuator according to the control function (CF) with the following “Tab. 3: Overview of pneumatic connections for actuator variants”.

Plug-in hose connectors

Hoses

Fig. 11: Assembly of pneumatic connections

NOTE!

Damageormalfunctionduetoingressofdirtandmoisture. ▶ To comply with degree of protection IP65 / IP67, install an exhaust air line on the unneeded pilot air port (for CFA, NC and CFB, NO) in the dry area.

Pilot air port 2 (P2)




Actuator1(left)

Actuator2(right)

Pilot air outputs for control head

Fig. 12: Pneumatic connection

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Pneumaticinstallation

Type2036 Actuator1 Actuator2

CF Connection CF Connection

D11, D55 CFA/CFA

CFA21 P1

P2: DeaerationCFA

22 P3

P4: Deaeration

D12 CFA/CFB

CFA21 P1

P2: Deaeration CFB22 P4

P3: Deaeration

D21 CFB/CFA

CFB21 P2

P1: DeaerationCFA

22 P3

P4: Deaeration

D22 CFB/CFB

CFB21 P2

P1: DeaerationCFB

22 P4

P3: Deaeration

Tab. 3: Overview of pneumatic connections for actuator variants

CFA, NC: Valve closed in rest position (by spring force)

CFB, NO: Valve open in rest position (by spring force)

For the assignment of control connections see the instal-lation and dimensional drawing included with delivery of the valve or in the Type 2036 operating instructions.

8 PNEUMATICINSTALLATIONThe dimensions of the feedback head / control head and the different complete device models, consisting of control, feedback head / control head, actuator and valve, can be found in the relevant data sheets.


DANGER!




WARNING!

Riskofinjuryfromimproperinstallation. ▶ Installation may only be carried out by authorized technicians with the appropriate tools.


▶ Secure system from unintentional activation. ▶ Following installation, ensure a controlled restart.

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Pneumaticinstallation

8.2 PneumaticinstallationoffeedbackheadType8685

The feedback head does not require a pilot air supply.

A description of the pneumatic installation of the actuator is included in the valve operating instructions.

8.3 PneumaticinstallationofcontrolheadType8686

DANGER!


Procedure:

→ Connect the control medium to the pilot air port (1) (6 – 7 bar; instrument air, free of oil, water and dust).

→ Mount the exhaust air line or a silencer on the exhaust air port (3) (see “Fig. 13: Pneumatic connection Type 8686”).

Important information for the problem-free functioning of the device:

▶ The installation must not cause back pressure to build up. ▶ To make the connection, select a hose with sufficient cross section.

▶ The exhaust air line must be designed in such a way that no water or other liquid can get into the device through the exhaust air connection (3).

Pilot air port Label: 1

Exhaust air port Label: 3

Fig. 13: Pneumatic connection Type 8686

Caution (exhaust air concept): In compliance with degree of protection IP65 / IP67, an exhaust air line must be installed in the dry area.

Always maintain an applied control pressure of at least 0.5 – 1 bar above the pressure which is required to move the actuator to its end position.

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Electricalinstallation

9 ELECTRICALINSTALLATION


DANGER!



WARNING!

Riskofinjuryfromimproperinstallation. ▶ Installation may only be carried out by authorized technicians with the appropriate tools.


▶ Secure system from unintentional activation. ▶ Following installation, ensure a controlled restart.

9.2 Deviceversion24VDC

9.2.1 ElectricalinstallationforfeedbackheadType8685

DeviceconnectionforcableglandType8685

→ Use a cable cross-section of 0.25 mm² for the electrical connection.

Fastening screws M4 (2x)

Screw terminals

Fig. 14: Position of screw terminals Type 8685

→ Loosen the fastening screws M4 and pull the feedback head up (only if the feedback head is already installed).

→ Install the cable gland, if necessary (approx. 1,5 Nm).

→ Guide the cables through the cable gland.

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GND24V

Top1

Bot1

Top2

Bot2

Fig. 15: Designation on PCB Type 8685

DesignationonPCB

Assignment1)

24 V Supply voltage + 24 V DC ±10%

GND Supply voltage - GND

Top 1 Top end position - Top actuator 1

24 V / 0 V (max. 0.1 A)GND

Bot 1 Bottom end position - Bot actuator 1

24 V / 0 V (max. 0.1 A)GND

Top 2 Top end position - Top actuator 2

24 V / 0 V (max. 0.1 A)GND

Bot 2 Bottom end position - Bot actuator 2

24 V / 0 V (max. 0.1 A)GND

Tab. 4: Connection for cable gland Type 8685

1) Actuator assignment see “Fig. 16”.





Actuator1(left)

Actuator2(right)


→ Connect the wires (see pin assignment in “Tab. 4”).

NOTE!

Damageormalfunctionduetoingressofdirtandmoisture. ▶ To ensure degree of protection IP65 / IP67, tighten the union nut of the cable gland according to the cable size you are using (approx. 1.5 Nm).

→ Tighten the union nut of the cable gland on the body (approx. 1.5 Nm).

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NOTE!

Faultydetectionofendpositions. ▶ For actuators with control function B (CFB, NO), the lower end position must be approached before the feedback head is placed on the adaptation body. To do this, pressurize the appropriate pilot air port of the actuator (“Fig. 9”).

▶ Make certain the feedback head is correctly positioned relative to the actuator: The dummy plug or pressure-relief valve must be located on the side of the pneumatic connections of the actuator (see “Fig. 9”).

→ Place the feedback head on the actuator. As you do, note: - The dummy plug or pressure-relief valve must be located on the

side of the pneumatic connections of the actuator.

- The caps must be in the starting position. If not, move the caps to the starting position (see “Fig. 5”)

- The switch spindles must lodge inside the recesses on the bottom of the feedback head. Do not move the caps onto the switch spindles.

→ Push the feedback head onto the adaptation body until no gap is visible on the form seal. Now align the mounting hole of the feedback head on each side with the square nut of the adaptation body.

NOTE!




→ Use the two fastening screws M4 and matching O-rings to fasten the feedback head onto the adaptation body (torque: 0.5 Nm ± 0.1 Nm).

When the supply voltage is applied, the feedback head is operating.

→ Before the device can be used, the basic settings (see section “10.3.1 Basic settings”) must still be made on the feedback head.

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9.2.2 ElectricalinstallationofcontrolheadType8686

Deviceconnectionforcircularplug-inconnectorType8686

→ Connect the circular plug-in connector of the control head as described in “Tab. 5”.

6

1

7

54

3

28

Fig. 17: Assignment of circular plug (M12 x 1, 8-pole)

Use only straight connecting socket.





Actuator1(left)

Actuator2(right)


When the supply voltage is applied, the control head is operating.

→ Before the device can be used, the basic settings (see section “10.3.1 Basic settings”) must still be made on the control head.

PinWirecolor2) Assignment3) Externalcircuit

1 whiteBottom end position - Bot actuator 2

24 V / 0 V (max. 0.1 A)GND (7)

1

2 brownTop end position - Top actuator 2

24 V / 0 V (max. 0.1 A)GND (7)

2

3 greenBottom end position - Bot actuator 1

24 V / 0 V (max. 0.1 A)GND (7)

3

4 yellowTop end position - Top actuator 1

24 V / 0 V (max. 0.1 A)GND (7)

4

5 grayValve control Y2 Actuator 2 activated

high active, to activate connect with 24 V

5

6 pinkValve control Y1 Actuator 1 activated


6

7 blue Supply voltage – GND7

88 red Supply voltage + 24 V DC ±10%

Tab. 5: Connection for circular plug-in connector Type 8686

2) The indicated colors refer to the connecting cable available as an accessory (919061).


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DeviceconnectionforcableglandType8686

→ Use a cable cross-section of 0.25 mm² for the electrical connection.

Fastening screws M4 (2x)

Screw terminalsCable holder

Fig. 19: Position of screw terminals Type 8686

→ Loosen the fastening screws M4 and pull the control head up (only if the control head is already installed).

→ Install the cable gland, if necessary (approx. 1,5 Nm).

Valve1

GND

24V

Valve2

Top1

Bot1

Top2

Bot2

Fig. 20: Designation on PCB Type 8686

→ Guide the cables through the cable gland.

→ Connect the wires (see pin assignment in “Tab. 6”).

DesignationonPCB

Assignment4) Externalcircuit

Bot2 Bottom end position - Bot actuator 2

24 V / 0 V (max. 0.1 A)GND

Top2 Top end position - Top actuator 2

24 V / 0 V (max. 0.1 A)GND

Bot1 Bottom end position - Bot actuator 1

24 V / 0 V (max. 0.1 A)GND

Top1 Top end position - Top actuator 1

24 V / 0 V (max. 0.1 A)GND

Valve2 Valve control Y2 Actuator 2 activated


Valve1 Valve control Y1 Actuator 1 activated


GND Supply voltage - GND

24V Supply voltage + 24 V DC ±10%

Tab. 6: Connection for cable gland Type 8686


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NOTE!

Malfunctionduetodamagedwires. ▶ To keep the spindle guides free, guide all wires through the cable holders.

Damageormalfunctionduetoingressofdirtandmoisture. ▶ To ensure degree of protection IP65 / IP67, tighten the union nut of the cable gland according to the cable size you are using (approx. 1.5 Nm).

→ Guide all wires through the cable holders.

→ Tighten the union nut of the cable gland on the body (approx. 1.5 Nm).

NOTE!

Faultydetectionofendpositions. ▶ For actuators with control function B (CFB, NO), the lower end position must be approached before the control head is placed on the adaptation body. To do this, pressurize the appropriate pilot air port of the actuator (“Fig. 9”).

▶ Make certain the control head is correctly positioned relative to the actuator: The dummy plug or pressure-relief valve must be located on the side of the pneumatic connections of the actuator (see “Fig. 9”).

→ Place the control head on the actuator. As you do, note: - The dummy plug or pressure-relief valve must be located on the

side of the pneumatic connections of the actuator.

- The caps must be in the starting position. If not, move the caps to the starting position (see “Fig. 5”)

- The switch spindles must lodge inside the recesses on the bottom of the control head. Do not move the caps onto the switch spindles.

→ Push the control head onto the adaptation body until no gap is visible on the form seal. Now align the mounting hole of the control head on each side with the square nut of the adaptation body.

NOTE!




→ Use the two fastening screws M4 and matching O-rings to fasten the control head onto the adaptation body (torque: 0.5 Nm ± 0.1 Nm).

When the supply voltage is applied, the control head is operating.

→ Before the device can be used, the basic settings (see section “10.3.1 Basic settings”) must still be made on the control head.

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9.3 DeviceversionAS-Interface

9.3.1 Electricalinstallationfeedbackheadandcontrolhead

The feedback head and control head are electrically connected by a multi-pole cable (M12 circular plug-in connector) and flat cable ter-minal. The circular plug can simply be connected with the flat cable terminal (see “Fig. 21”).

Screws

M12 plug-in con-nector branch circuit

Fig. 21: Feedback head / control head with multi-pole cable and flat cable terminal

Wiring diagram of circular plug M12

The view shows the image from the front looking at the pins, the solder connections are behind them.

Pin 4:

NC

Pin 1:

Bus +

Pin 3:

Bus –

Pin 2:

NC

Fig. 22: Bus connection

Pin Designation Assignment

1 Bus + AS-Interface bus line +

2 NC not used

3 Bus – AS-Interface bus line –

4 NC not used

Tab. 7: Pin assignment of circular plug-in connector for AS-Interface

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Handlingtheflatcableterminal

The multi-pole cable features a flat cable terminal - with M12 plug-in connector branch circuit - for AS-Interface cable harness. The flat cable terminal contacts the AS-Interface flat cable by means of penetration technology which allows installation by “clipping in” the AS-Interface flat cable without cutting and without removing insulation.

Procedure:

→ Open the flat cable terminal (loosen screws and remove cover).

→ Insert flat cable to fit closely.

→ Close flat cable terminal again.

→ Tighten the screws Loosen the thread-forming screws slightly (approx. 3/4 turn to the left) and position them on the existing threaded hole and screw in.

9.3.2 AS-Interfaceconnection

AS-Interface (Actuator Sensor Interface) is a field bus system which is used primarily for networking binary sensors and actuators (slaves) with a higher-level control (master).

Busline

Unshielded two-wire line (AS-Interface line as AS-Interface flat cable) along which both information (data) and energy (power supply voltage for the actuators and sensors) are transmitted.

Networktopology

Freely selectable within wide limits, i.e. star, tree and line networks are possible. Further details are described in the AS-Interface Spec-ification (A/B slave model conforms to the version 3.0 specification

9.3.3 TechnicalDataforAS-InterfacePCBs

Supply: via AS-Interface (29.5 V – 31.6 V)

Control head outputs: Valve Y1 and valve Y2, each with max. 0.8 W, Power reduction after approx. 100 ms with integrated watchdog function

Certification: Feedback head: Certificate No. 94701 based on version 3.0

Control head: Certificate No. 94801 based on version 3.0

9.3.4 Programmingdata

ProgrammingdataforfeedbackheadType8685

I/O configuration 0 hex

ID codeA hex (see below for bit configuration)

Extended ID code 1 7 hex

Extended ID code 2 E hex

Profile S-0.A.E

Tab. 8: Programming data for feedback head Type 8685

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Bitconfiguration

DatabitInputs

Function Assignment5)

D0Top end position - Top actuator 1

0 Top not reached 1 Top reached

D1Bottom end position - Bot actuator 1

0 Bot not reached 1 Bot reached





DatabitOutputs


D0 - not used

D1 - not used

D2 - not used

D3 - not used

Tab. 9: Bit configuration of AS-Interface for feedback head Type 8685

Parameter bits have no function.


ProgrammingdataforcontrolheadType8686:

I/O configuration 7 hex

ID code A hex (see below for bit configuration)

Extended ID code 1 7 hex

Extended ID code 2 E hex

Profile S-7.A.E

Tab. 10: Programming data for control head Type 8686





Actuator1(left)

Actuator2(right)


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Bitconfiguration

DatabitInputs










DatabitOutputs


D0 Pilot valve Y10 Pilot valve OFF 1 Pilot valve ON

D1 Pilot valve Y20 Pilot valve OFF 1 Pilot valve ON

D2 - not used

D3 - not used

Tab. 11: Bit configuration of AS-Interface for control head Type 8686

Parameter bits have no function.


9.3.5 LEDstatusdisplayforAS-Interface

StatusLED1(green)

StatusLED2(red)

off off POWER OFF

off onNo data traffic (expired Watch Dog at slave address does not equal 0)

on off OK

flashing on Slave address equals 0

Tab. 12: LED status display for AS-Interface





Actuator1(left)

Actuator2(right)


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Controlanddisplay

10 CONTROLANDDISPLAY

10.1 ControlanddisplayelementsforfeedbackheadType8685

10.1.1 Deviceversion24VDC

The items listed below are designed separately for actuator 1 and 2.

Displayelements:

• Status of actuator (end position)

The display elements are designed in the form of an LED.

Controlelements:

• DIP switch for selecting actuator size RV50, RV70, RV110

• Slide switch for color selection of end position

If the transparent cap is unscrewed, follow the instructions in “Step 4: Closing the transparent cap / body casing”, page 36.

DIP switch - actuator 1


Slide switch Color selection of end position Actuator 2


Actuator 1

LEDs Status of actuator 2 (end position)

LEDs Status of actuator 1

(end position)

Fig. 25: Control and display elements for 24 V DC feedback head

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Controlanddisplay

10.1.2 DeviceversionAS-Interface

Other than the AS-Interface bus status, the items listed below are designed separately for actuator 1 and 2.

Displayelements:

• AS-Interface bus status



Controlelements:



If the transparent cap is unscrewed, follow the instructions in “Step 4: Closing the transparent cap / body casing”, page 36.

LEDs AS Interface bus status



Slide switch for color selection of end position Actuator 2

Slide switch for color selection of end position

Actuator 1



(end position)

Fig. 26: Control and display elements for AS-Interface feedback head

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Controlanddisplay

10.2 ControlanddisplayelementsforcontrolheadType8686

The items listed below are designed separately for actuator 1 and 2.

Device versions 24 V DC and AS-Interface have the same display and control PCB.

The AS-Interface bus status LEDs are accordingly inactive for the 24 V DC device version.

Displayelements:

• AS-Interface bus status


• Status of pilot valve


Controlelements:



• Slide switch for direct activation of pilot valves (service switch)

If the transparent cap / the body casing is unscrewed, follow the instructions in “Step 4: Closing the transparent cap / body casing”, page 36.



Slide switch Color selection of end position Actuator 2


Actuator 1

Slide switch (service switch) Pilot valve for actuator 2

Slide switch (service switch)

Pilot valve for actuator 1

LED status of pilot valve Actuator 2

LED status of pilot valve Actuator 1

LEDs AS Interface bus status



(end position)

Fig. 27: Control and display elements - control head

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Controlanddisplay

10.3 Control

10.3.1 Basicsettings

To ensure the function of Types 8685 and 8686, these basic set-tings must be made before start-up in the isolated state.

DANGER!



→ Unscrew the transparent cap.

→ Perform steps 1 to 4.

Step1:Selecttheactuatorsize

The control elements are designed for one actuator side only.

Switch only one DIP switch element per actuator size to active, depending on the actuator size (see actuator type label). Only one uniform actuator size needs to be selected on both actuator sides.

Incorrect settings of the DIP switches result in malfunctions or no function of the end position feedback.

→ Pushing a DIP switch element to the “ON” position causes the end position sensors of the selected actuator size to be activated.

RV110RV70RV50

ACTUATOR

12

3

ON

ONType 8685

Type 8686

Fig. 28: Selection of actuator size via DIP switch

Step2:ChangetheassignmentoftheendpositionLEDs(actuatorstatus)

You can set the color assignment of the end positions with these slide switches. You can indicate for each color whether it applies to the Top (upper end position) or Bot (lower end position).

The slide switches for color selection must be unam-biguously selected inside the actuator chamber, i.e. both switches must be up or both must be down.

Incorrect settings of these switches will result in an incorrect visual interpretation of end position detection, but the end position detection will still be correct.

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Controlanddisplay

Bot

gn ye

Bot

Top

Top

Typ 8685

Typ 8686

Fig. 29: Color assignment of end positions via slide switch

Refer to the PCB labeling in the table below

Switchpositionforoneactuatorside

ActuatorstatusLED

Both switches up End position Top yellow / End position Bot green

Both switches down End position Top green / End position Bot yellow

Switch up/down - Invalid state -

Switch down/up - Invalid state -

Tab. 13: Color assignment of end positions

The following function is set in the factory:

Color Actuatorstatus

Green LED lit Lower end position

Yellow LED lit Upper end position

Tab. 14: Assignment of status of actuator LEDs (end position)

Step3:Referencemovementforspindleadjustment

To make the fine adjustment of the spindle for actuator size, it is essential to move both spindles from the lower to the top end position.

ProcedureforType8685:

Actuator with design control function A (CFA, NC):

→ Under maximum control pressure, move the spindles up by acti-vating the actuator chambers.

→ After the end position is reached (preselected LED is lit), turn off the control pressure. The spindle moves to the lower end position. LED for end position Bot is lit with the selected color.

Actuator with design control function B (CFB, NO):

→ Under maximum control pressure, move the spindles down by activating the actuator chambers.

→ After the end position is reached (preselected LED is lit), turn off the control pressure. The spindle moves to the upper end position. The corresponding LED for the end position is lit with the selected color.

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Controlanddisplay

ProcedureforType8686:

→ Under maximum control pressure, switch the service switch to “On”. The spindle moves to the upper end position.

→ After the end position is reached (preselected actuator status LED is lit), switch the service switch back to “Off”. The spindle moves to its initial position. The corresponding actuator status LED for the end position is lit with the selected color.

ON

Service

OFF

Service

ON OFF

Service switch

Pilot valve status LED

Fig. 30: Spindle adjustment

Step4:Closingthetransparentcap/bodycasing

→ Check that the seal is correctly positioned in the transparent cap / body casing (see “Fig. 31”).

NOTE!

Damageormalfunctionduetoingressofdirtandmoisture. ▶ To comply with degree of protection IP65 / IP67, screw in the transparent cap / body casing all the way.

→ Close the transparent cap / body casing (auxiliary tool for installing the cover: 6740777)).

Seal body casing

Body casing

Type 8686

Type 8685

Seal transparent cap

Transparent cap

Fig. 31: Position of the seal in the transparent cap / body casing

The device is now configured and ready for operation.

7) The auxiliary tool for installing the cover (674077) is available through your Bürkert sales office.

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Controlanddisplay

10.3.2 Changingthesettings

Procedure:

→ Unscrewing the transparent cap makes the slide switches and DIP switches accessible.

→ Select the actuator size with the DIP switches. Only one uniform actuator size needs to be selected on both actuator sides (see valve type label).

→ Use the “Tab. 13: Color assignment of end positions” or the labeling on the PCB to assign the desired color to the actuator status LEDs (end position).


NOTE!




10.3.3 ManualactivationofpilotvalveswiththecontrolheadType8686

The pilot valves can be switched with the service switches. With control function A, the spindle moves up with switch position “On”. With control function A, the spindle moves down with switch position “On”.

ON

Service

OFF

Service

ON OFF

Slide switch (service switch)

Pilot valve for actuator 1

LED status Pilot valve for actuator 2

Slide switch (service switch) Pilot valve for actuator 2

LED status Pilot valve for actuator 1

Fig. 32: Service switch and status LEDs for pilot valve (Type 8686)

Procedure:

Voltage is absolutely essential on the device!

→ Unscrewing the transparent cap makes the service switches accessible.

→ Switch the relevant pilot valve with the service switches.


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Controlanddisplay

NOTE!



ProcedureforreplacingthediaphragmforType2036

Voltage is absolutely essential on the device!

→ Unscrewing the transparent cap makes the service switches accessible.

→ Replace the diaphragm as described in the operating instruc-tions for Type 2036.

→ After the diaphragm is replaced, perform a reference movement for spindle adjustment (see “10.3.1 Basic settings”, step 3).


NOTE!


→ Close the transparent cap (auxiliary tool for installing the cover: 6740779)).

Seal body casing

Body casing

Type 8686

Fig. 33: Position of the seal in the body casing


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Safetypositions

11 SAFETYPOSITIONSSafety positions after failure of the electrical or pneumatic auxiliary power:

Actuatortype

DesignationSafetypositionsafterfailure

oftheauxiliarypower

electrical pneumatic

up

down

single-acting

Control function A

down down

up

down

single-acting

Control function B

up up

Tab. 15: Safety positions

12 MAINTENANCE


DANGER!




WARNING!

Riskofinjuryfromimpropermaintenance. ▶ Maintenance may only be carried out by authorized technicians with the appropriate tools.


▶ Secure system from unintentional activation. ▶ Following maintenance, ensure a controlled restart.

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Maintenance

12.2 Serviceattheairintakefilter

DANGER!


To protect the internal pilot valves and the actuator, the control air is filtered.

The direction of flow of the air intake filter in installed state is from the inside to the outside through the filter material.

Air intake filter

Quick connector

O-ring

Fig. 34: Service at the air intake filter

Procedure:

→ Unlock the quick connector by pressing the holding element and pulling out the air intake filter (if necessary, use a suitable tool in between the recesses in the head of the filter).

→ Clean the filter or, if necessary, replace the filter.

→ Check inner O-ring and, if required, clean.

→ Insert the air intake filter all the way into the quick connector.

DANGER!

Riskofinjuryduetoimproperinstallation. ▶ Ensure that the air intake filter is installed correctly.

→ Check that the air intake filter is secure.

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Malfunctions

13 MALFUNCTIONS

Malfunction Causeandremedialaction

End position is not detected

No or inadequate supply voltage

→ Check the electrical connection and supply voltage

Wrong size of switch spindles from the adapter set

→ Replace switch spindles

Wrong spindle lead-through selected for spindle installation

→ Push the switch spindle through the matching spindle lead-through

Wrong actuator size selected with the DIP switches

→ Select the matching actuator size

Cap of the switch spindle moved by force during assembly

→ Remove the feedback head / control head

→ Pull the cap towards the end of the switch spindle until you can see one groove

→ Install the feedback head / control head

→ Perform a reference movement for spindle adjustment


Faulty detection of end position

Wrong actuator size selected with the DIP switches


More than one actuator size selected with the DIP switches


Feedback head / control head not mounted in the correct position

→ Mount the feedback head / control head in the correct position (see “Fig. 9”)

Incorrect display of actuator status LED

Color selection switch not correctly selected

→ Select the color assignment correctly (both up or both down, see section “10.3.1 Basic settings” “Fig. 29”)

Actuator does not switch


→ Check the electrical connection and supply voltage

Pressure supply too low

→ Check the control pressure

Faulty hose system

→ Check the pneumatic connections

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Malfunctions


AS-Interface bus status LEDs off


→ Check contact of ribbon cable terminal with AS-Interface line

→ Ensure supply voltage is present on the AS-Interface line

Tab. 16: Malfunctions

14 SHUTDOWN


DANGER!




WARNING!

Riskofinjuryfromimproperremoval. ▶ Removal may be carried out by authorized technicians only and with the appropriate tools.

14.2 Disassembly

Procedure:

→ Turn off the pressure and vent the lines.

→ Switch off the power supply.

1. Pneumatic connection (control head Type 8686 only)

DANGER!


→ Loosen pneumatic connection.

→ Release the pneumatic connection to the actuator.

3. Mechanical connections

→ Release the fastening screws.

→ Pull the feedback head / control head up and out.

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Malfunctions

2. Electrical connection

DANGER!



Device with circular plug-in connector:

→ Release the circular plug.

Device with cable gland:

→ Release the cable gland.

→ Loosen the wires from the screw terminals.

Control head Type 8686

Electrical connection

Pneumatic connection

Fastening screw (2x)

Pneumatic connection with actuator

Actuator

Feedback head Type 8685

Fastening screw (2x)

Actuator

Fig. 35: Disassembly

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Accessories

16 TRANSPORT,STORAGE,PACKAGING

NOTE!

Transportdamage.

Inadequately protected equipment may be damaged during transportation.

▶ During transportation protect the device against moisture and dirt in shock-resistant packaging.

▶ Prevent the temperature from exceeding or dropping below the permitted storage temperature.

▶ Protect the electrical interfaces of the coil and the pneumatic connections from damage by placing protective caps on them.

Incorrectstoragemaydamagethedevice. ▶ Store the device in a dry and dust-free location. ▶ Storage temperature -20 – 65 °C.

Damagetotheenvironmentcausedbydevicecomponentscontaminatedwithmedia.

▶ Ensure the device and packaging are disposed of in an environ-mentally sound manner.

▶ Observe applicable regulations relating to refuse disposal and the environment.

15 ACCESSORIES

Designation Orderno.

Connecting cable M12 x 1, 8-pole 919061

Auxiliary tool for installing the transparent cap 674077

Tab. 17: Accessories

English

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www.burkert.com

type 8685 / 8686

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